Pocket door for modular partition system

ABSTRACT

A pocket door panel for use within a modular partition system is based upon a standard partition panel having vertical end members joined by spaced horizontal C-section members secured to opposite sides of the vertical end members with the mouths of the C-section members facing outwardly. The pocket door panel has one vertical end member replaced by two J-section members secured to the horizontal members and defining an elongated vertical opening between them. A generally rectangular door is adapted to slide horizontally into the opening and the pocket within the panel defined by the horizontal members. Rollers are mounted within the panel above and below the door to engage the top and bottom of the door and guide the horizontal sliding movement of the door. The inner edge of the door includes a leveling device that slidably engages one or more horizontal members to prevent the vertical movement of the inner edge of the door.

[0001] The present invention is a continuation-in-part of patent application Ser. No. 09/586,894 filed Jun. 5, 2000. application Ser. No. 09/586,894 is incorporated herein and made a part of the present application.

FIELD OF THE INVENTION

[0002] This invention relates to modular partition systems such as are used to partition office or other workspace, and to support work surfaces and storage and other modules.

BACKGROUND OF THE INVENTION

[0003] Such systems are typically formed of vertical panels which are interconnected at their edges to form desired partitions. Such systems impose both horizontal and vertical modularity on the resulting structure. The horizontal modularity entails that the dimensions of the walls of the structure can be varied only in increments imposed by available panel sizes. There is also a problem accommodating cabling which must be threaded through the ends of the panels and is difficult to alter after the system is installed. Some such systems make use of panel frames with clip-on cladding, as exemplified by U.S. Pat. No. 5,406,760 (Edwards) in which the panels comprise horizontal frame members disposed outwardly of vertical frame members such that, when panels are secured together in the same plane, the horizontal members are aligned to form continuous rails on which furnishings may be located horizontally without regard to the modularity of the panels. Cabling may be passed horizontally between the outside panels and the vertical members, and vertically between the horizontal members, facilitating cabling.

[0004] U.S. Pat. No. 5,582,904 also uses panels having narrow vertical members and spaced horizontal box beams of greater width supporting external cladding and providing channels which locate clips supporting furnishings or panels at any desired horizontal location. The box beams are provided with vertical pass-through to permit vertical cabling, horizontal cabling being accommodated between the box beams. The latter nevertheless are complex fabrications, and complicate assembly of the panels.

SUMMARY OF THE INVENTION

[0005] In is an object of the present invention to provide a partitioning system which provides for flexible location of furnishings, and junctions between partition walls, yet can be assembled from simple modular components.

[0006] The invention relies on a panel frame structure comprised of vertical members of substantially lesser thickness than the panels to be formed, which may be joined end-to-end in a modular manner, and side-by-side to join vertical ends of adjacent panels, and horizontal C-section rails secured to opposite sides of the vertical rails with mouths of the C-sections facing outwardly. Cladding panels are secured by vertically-spaced sets of spring clips engaging respectively upper and lower surfaces of vertically-spaced horizontal rails, and worksurfaces and other furnishings are secured to a clamp member engaged within the C-section of horizontal rails. The relationship of the horizontal and vertical members allows for easy cabling, and the use of the clamps permits panels and furnishings to be located without substantial regard to the horizontal modularity of the system. The basic panelling system requires a minimum number of different modular parts.

[0007] Accordingly, the invention provides a partitioning system having a panel frame structure, each panel frame having vertical end members arranged in a common plane and adapted to be joined end-to-end with those of other panels, and horizontal frame members arranged in vertically-spaced pairs and secured to opposite side faces of the vertical members, the horizontal members each being of C-section with openings of the C-sections facing outwardly. Preferably the system further includes cladding panels and clips securing the panels to the frame structure externally of the horizontal members, or the clips being secured to the panels and engaging a top surface of one horizontal member, and a bottom surface of another horizontal member vertically spaced from said one horizontal member on the same side of the frame structure.

[0008] Preferably, the system also includes at least one clamp member entering a horizontal member through the opening of its C-section and releasably clamped therein, and at least one of a furnishing support, a work surface and a further panel attached to the clamp member.

[0009] In another aspect, the present invention includes a pocket door panel for use in a partitioning system, the partitioning system having a panel frame structure, the pocket door panel including a panel frame arranged in a vertical plane, having a cavity therein, and having an elongated vertical opening at an end perpendicular to the vertical plane, the opening being in communication with the cavity; a door arranged in a vertical plane, having a top and a bottom edge and adapted to slidably enter the cavity through the opening, the door having a closed position and an open position and being horizontally moveable between the closed position and the open position; and rollers mounted on the panel frame within the cavity and adapted to engage the top edge and the bottom edge of the door to slidably guide the door between the open and closed positions.

[0010] In yet another aspect, the pocket door panel further includes a leveling device attached to a vertical edge of the door and slidably engaging a horizontal member of the panel frame to prevent the edge of the door from moving vertically and/or laterally.

[0011] The invention is described further below with reference to a presently-preferred embodiment as illustrated by the accompanying drawings:

SHORT DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is an isometric view showing basic frame modules forming the basis of a preferred embodiment of the invention.

[0013]FIG. 2 is a fragmentary isometric view illustrating how adjacent coplanar frames are connected;

[0014]FIG. 3 is an end view of a partition formed of assembled frame modules with panels attached;

[0015]FIG. 4 is an isometric view illustrating the connection of four partitions of different heights at their vertical edges;

[0016]FIG. 5 is a fragmentary end view of a panel frame illustrating the attachment of cladding panels and of brackets supporting furnishings or other panel frames;

[0017]FIG. 6 is an isometric view of a cladding panel prior to attachment;

[0018]FIGS. 7 through 10 are fragmentary isometric views of brackets for supporting panels, furnishing units and work surfaces at points intermediate the length of panel frames;

[0019]FIG. 11 is an isometric view of a leveler foot at the base of a column of a panel frame;

[0020]FIG. 12 is a fragmentary isometric view of an alternative form of cladding panel;

[0021]FIG. 13 is an isometric view of a partition unit incorporating cable organizers so as to provide a raceway at any height on either face of a panel frame;

[0022]FIG. 14 is an isometric view of a cable organizer;

[0023]FIG. 15 is an isometric view illustrating the mounting of window panels;

[0024]FIG. 16 is an isometric view of a pocket door panel and a sliding door;

[0025]FIG. 17 is an exploded isometric view of a pocket door panel and a sliding door;

[0026]FIG. 18 is a fragmentary isometric view of a roller unit, threaded rods and nuts for use in connection with a pocket door panel and sliding door;

[0027]FIG. 19 is an isometric view of a roller unit including reinforcing metal plates;

[0028]FIG. 20 is an isometric view of a roller unit without reinforcing metal plates;

[0029]FIG. 21 is a fragmentary isometric view of a leveling device according to the present invention; and

[0030]FIG. 22 is a fragmentary isometric view of another leveling device according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0031] Referring to FIG. 1, at least the spines of partitions in a system according to the invention are made up of panel frame modules; in the example shown, a 105 cm high base module 2 which may be built up to any desired panel height by the addition of 60 cm and or 30 cm modules 4 and 6. The individual modules are made up of vertical end members 8 of hollow rectangular section, and C-section horizontal members 10 secured by fasteners or otherwise to the vertical members with the opening 12 of each C-section facing outwards. Additional intermediate vertical members (not shown) can be added, if required, either during installation or at any time thereafter, being secured to the horizontal members by fasteners passing through the holes 14.

[0032] The vertical members 8 of the modules may be connected by tongues 16 fitting within and secured by fasteners to the rectangular sections. Adjacent panel frames may be connected as shown in FIG. 2 by bolts 20. This figure also shows the fasteners, in this example screws 18, securing the horizontal members. The panels are completed as shown in FIG. 3 by clipping cladding tiles 22 or other cladding elements such as raceway covers 24 to the upper and lower external surfaces of the horizontal members 10 as seen in FIG. 3. The cladding tiles may be installed and removed independently without interference with adjacent tiles. Tiles may be interchanged to renovate the system or to suit decorative schemes. Each vertical member 8 is provided at its lower end with a levelling foot 26 (see FIG. 11) having a threaded shaft 20 which screws into a bracket 28 secured by a screw 30 in engagement with the member 8. The offset position of the levelling foot and its shaft 20 relative to the member 8 facilitates levelling of panels whether manually or using a power tool. A scuff protector 31 may be clipped to the lowest members 10 to close the gap between the panels 22 and the floor.

[0033] At the intersection of three or four panels, the panels may be secured, instead of by bolts 20, by shorter bolts 32, engaging turned-up flanges of cups 34, as best seen in FIG. 4, which also shows the frames 36 of cladding tiles 22, as well as raceway covers 24. As shown, panels of different heights may be connected in this manner.

[0034] As best seen in FIG. 5, the C-shaped horizontal members support the cladding tiles 22 and raceway covers, by means of spring clips 40, which may be installed on raised lances or secured with fasteners to the frame of the tile. As seen in FIG. 6, oppositely-acting rows of these clips are secured to the frame 36 of the tile.

[0035] Heavier duty connections to the panel frames intermediate the module lengths are made through brackets as shown in FIGS. 5 and 7 to 9. A portion 42 of each bracket forms a cantilever with an inclined distal portion 44 which is easily inserted within the C-section of a horizontal member so as to engage its bottom wall. It can then be clamped in place by a clamp member 46 which engages the top and upper outer walls of the C-section and is secured in place by fasteners, in this case, a screw or screws 48. The outer end 50 of the cantilever formed by the portion 42 may take various forms, according to application. In FIGS. 5 and 8, it is turned downwardly (or upwardly if the bracket is mounted upside down as seen at the bottom of Figure) to support a bracket 52 or brackets 52 and 54, used to support heavy furnishings such as cabinets. The clamp member 46 may include a projecting tab 47 designed to lock into a corresponding slot in the back of a cabinet (not shown) to lock the latter in place on the bracket.

[0036] In FIG. 7, each portion 50 may support a bolt 56, enabling a panel 58 to be secured perpendicular to the first panel at any point along the length of a panel 60.

[0037] In FIG. 9, the end 50 is turned outward horizontally and forms a mounting plate 62 which supports a work surface 64 to which it is secured by screws 66.

[0038] In FIG. 10, an inner end of a bracket 67 is upturned (not shown) to engage within an upper portion of a C-section, while its outer end is cranked outwardly and secured by a screw 69 or other fastener to the top of an auxiliary column 68 which is provided with a vertical row of vertical slots 70 to accept cantilever brackets such as the bracket 72. The reaction from a work surface 64 supported by such a bracket is sustained by a leveler foot at a lower end of the column 68 which bears all the vertical load applied through the bracket, while screw 74 bearing on a lower horizontal member sustains torsional loads, which screw may be turned to adjust the angle of the work surface.

[0039] It will be appreciated that the brackets described above with reference to FIGS. 5-10 permit installation of branch panels, work surfaces, cabinets and shelving at any point along a spine formed by the panels, without regard to the horizontal modularity of the latter.

[0040]FIG. 12 shows a form of panel 78 which may be used in place of a panel 22, and presents a series of horizontal C and G-section channels 76 which may support various types of brackets supporting furnishings which can then be moved horizontally without regard to the modularity of the panel frame.

[0041] It is a feature of the panel system of the present invention that the horizontal C-section members 10 provide stand offs for the cladding tiles 22 and other cladding elements from the vertical columns 8, allowing ample space between the tiles and the columns for raceways 80 (see FIGS. 3 and 13). Brackets 82 secured between members 10 on opposite sides of the vertical members provide support for modules of modular electric bus equipment 92, such as outlets and connectors which may be installed at any desired height, while cable organizers 86 have base members having tabs 87 which lock into slots 89 in the members 10 (see FIG. 1), and hinged side flaps 88 which allow cables 90 to be inserted into them.

[0042] It will be seen that the basic partition structure described so far can be made up from a relatively small inventory of parts. While the panel frame modules 2, 4 and 6 may be pre-assembled, they are formed from lengths of rectangular section tube, lengths of C-section, plates forming the tongues 16, and the brackets 82. While the parts may be bolted together, it may be preferable in pre-assembled modules to weld the parts together. The cladding tiles comprise simple frames 36 to which the clips 40 are attached, with a fabric or other cladding, while the raceway covers may be pressed from sheet metal and the clips 40 attached. In suitable locations, the cladding tiles may be replaced by window units, or soundproof or other panels. As seen in FIG. 15, window units may be formed with head and sill members 94 which may be plastic extrusions and clip onto respectively lower and upper halves of the C-section members 10, and stiles 95 which may similarly be plastic extrusions and clip around vertical members 8 to provide together a frame retaining a glazing or other panel 96. This figure also shows how a panel may be fitted with a top trim 98 clipped over upper portions of C-section members 10. Heavier duty connections to branch panels or other furnishings may be made in a module independent manner using the clamps described with reference to FIGS. 5 and 7 through 10, again using a minimal number of basic parts and no tools other than wrenches and screwdrivers.

[0043] The raceways 80 provide ample space for horizontal cable runs, while plenty of space for vertical runs and modular bus units is provided between the horizontal rails 20. The cables are easily installed, and panels can be moved without cutting existing cables.

[0044] Reference is now made to FIGS. 16 and 17 which show a panel 102 adapted to accommodate a sliding door 100. The panel 102 is similar to the panel described above in that it includes the vertical end member 8 and C-section horizontal members 10. One vertical end member 8 of the panel 102 is replaced with two spaced vertical pocket members 104 that define an opening 106 for the sliding door 100. The pocket members 104 are J-section members secured by fasteners or otherwise to the horizontal members 10. Brackets 82 are secured between horizontal members 10 at the top and bottom of the panel 102. Also secured between horizontal members 10 at the top and bottom of the panel are roller units 108 (FIG. 18) which are positioned with their axes of rotation perpendicular to the plane of the panel 102. Each roller unit 108 is secured between the horizontal members 10 by threaded rods 120 and nuts 122 (FIG. 18).

[0045] The sliding door 100 includes a top frame member 110, a bottom frame member 112, an inner vertical frame member 114 and an outer vertical frame member 116. The frame members 110, 112, 114 and 116 define a generally vertical plane containing the sliding door 100, and are joined in a generally rectangular configuration. The sliding door 100 is operable to slide horizontally within the panel 102 between opposing horizontal members 10. The top and bottom frame members 110 engage the top and bottom roller units 108 to facilitate and guide the horizontal movement of the sliding door 100.

[0046] Reference is now made to FIGS. 19 and 20, which show an isometric view of a roller unit 108. The roller unit 108 includes a plastic housing 124 which contains a die-cast assembly 126. Two plastic rollers 128 are mounted upon the outside end of the die-cast assembly 126. The die-cast assembly 126 is slidably mounted to the plastic housing 124 such that the distance of the plastic roller 128 from the plastic housing 124 is adjustable. The die-cast assembly 126 is secured in a position by means of an adjusting screw in the threaded adjustment hole 132. The adjusting screw exerts frictional pressure upon the die-cast assembly 126 to prevent any further movement relative to the plastic housing 124. The die-cast assembly 126 may have horizontal ridges or notches upon its surface that engage the adjustment screw so as fix the die-cast assembly in place and prevent further movement. The plastic housing 124 has four mounting holes 134 for securing the roller unit 108 to a structure. The mounting holes 134 accommodate the threaded rods 120 (FIG. 18). In this embodiment, the plastic housing 124, die-cast assembly 126 and plastic rollers 128 are a commercially available pre-assembled unit.

[0047] As shown in FIG. 19, the plastic housing 124 is reinforced by metal plates 130 placed on either side of the plastic housing 124. The metal plates 130 are adapted to reinforce the plastic housing 124 while accommodating the threaded rods 120 through the mounting holes 134 and the slidably adjustable movement of the die-cast assembly 126. In a further embodiment, the plastic rollers 128 and die-cast assembly are tension mounted to the plastic housing 124, for example, by a spring, to ensure the plastic rollers 128 firmly and securely engage the top and bottom frame members 110 and 112.

[0048] Referring now to FIG. 21, the movement of the sliding door 100 is further guided and controlled through the cooperation of one or more of the horizontal members 10 and of a leveling device 118 secured to the inner vertical frame member 114. The leveling device 118 slidably engages the one or more horizontal members 10, preventing the vertical movement of the inner vertical frame member 114 due to any force upon the outer vertical frame member 116. This prevents distortion of the generally rectangular frame of the sliding door 100 and prevents the sliding door 100 from pitching forwards as it slides outward from the panel 102. In one embodiment, the leveling device 118 comprises a bracket mounted upon the inner vertical frame member 114, the bracket having mounted thereupon two or more rollers adapted to engage the upper and lower surfaces of a horizontal member 10.

[0049] The stationary top and bottom rollers 108 and the leveling device 118 permit the sliding door 100 to operate free of any contact with elements external to the panel 102. The sliding door 100 requires no contact with the floor upon which the panel 102 sits, nor any contact with the ceiling or a door frame extending over the doorway opening. Accordingly, the panel 102 and sliding door 100 are a modular unit usable in connection with the modular partition system. The pocket door panel 102 may be installed next to any other conventional panel of the modular partition system.

[0050]FIG. 22 shows a further embodiment of a leveling device 140. The leveling device 140 is secured to the inner vertical frame member 114 using an appropriate fastener. The leveling device 140 comprises an upper bracket 142 and a lower bracket 144. Each bracket 142, 144 comprises a front face 146 abutting the surface of the inner vertical frame member 114, vertical outer faces 148 extending therefrom in vertical planes parallel to the direction of sliding movement of the sliding door 100 and horizontal flanges 150 extending outwards from the vertical outer faces 148. The vertical outer faces 148 and flanges 150 of the brackets 142, 144 form a c-shaped channel for receiving a horizontal member 10 on either side of the brackets 142, 144. The inner surfaces of the c-shaped channel formed by the brackets 142, 144 are provided with a low friction material 152 to enable low-friction sliding engagement with the horizontal members 10. The brackets 142, 144, in cooperation with the horizontal members 10, permit the sliding door 100 to slide horizontally in the direction of its plane, but prevent vertical and/or lateral movement.

[0051] The basic panels which form the spine of the system do not depend on the attachment of legs, work surfaces or other furnishings for their rigidity, and tables, desk or other moveable furniture may be placed adjacent the panels without being attached to them.

[0052] The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Certain adaptations and modifications of the invention will be obvious to those skilled in the art. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. 

I claim:
 1. A pocket door panel for use in a partitioning system, the partitioning system having a panel frame structure, the pocket door panel comprising: (a) a panel frame arranged in a vertical plane, having a cavity therein, and having an elongated vertical opening at an end perpendicular to said vertical plane, said opening being in communication with said cavity; (b) a door arranged in said vertical plane, having top, bottom and side frame members, and being adapted to slidably enter said cavity through said opening, said door having a closed position and an open position and being horizontally movable between said closed position and said open position; and (c) rollers mounted on said panel frame within said cavity and adapted to engage said top and bottom frame members to slidably guide said door between said positions.
 2. A pocket door panel for use in a partitioning system, the partitioning system having a panel frame structure, the pocket door panel comprising: (a) a panel frame arranged in a vertical plane having a vertical end frame member and a vertical pocket end frame member spread apart and arranged perpendicular to said vertical plane, said vertical pocket end frame member defining an elongated vertical opening, and having horizontal frame members arranged parallel to said vertical plane in vertically spaced pairs and secured to said vertical end frame member and said vertical pocket end frame member; (b) bottom rollers secured between a bottom pair of said horizontal frame members and top rollers secured between a top pair of said horizontal frame members; and (c) a door comprising a horizontal top, a horizontal bottom, a vertical leading and a vertical trailing door member, said door members being connected to generally define a rectangle in said common plane, said door being adapted to slide horizontally within said opening between an open position and a closed position, and wherein said top door member engages said top rollers and said bottom door member engages said bottom rollers.
 3. The pocket door panel of claim 2, wherein said vertical trailing door member is located between said vertical end frame member and said vertical pocket end frame member of said panel frame, the pocket door panel further comprising a leveling device secured to said trailing door member and slidably engaging at least one of said horizontal frame members to prevent vertical movement of said trailing door member when the door is slid between an open and closed position.
 4. The pocket door panel of claim 2, wherein each said roller comprises a housing, a wheel support member slidably mounted to said housing, a wheel rotatably mounted upon said wheel support member and an adjustment means and wherein said housing is secured between said horizontal frame members, said wheel support member is slidably operable to adjust the vertical distance between said wheel and said housing so that said wheel may engage said door member, and said adjustment means is operable to fix said wheel support member in place.
 5. The pocket door panel of claim 4, wherein said adjustment means is a screw.
 6. The pocket door panel of claim 2, wherein at least one of said rollers is tension mounted such that said rollers firmly engage said top and bottom door members.
 7. The pocket door of claim 2, wherein said vertical pocket end frame member comprises two vertical j-section members spaced apart, the space therebetween defining said opening. 